m05100k61b014 Ct85 - 91 - 95HR SVC Manual

Models 8500, 9100, and 9500HR Total Body Cross-Trainers with Rear Drive System
Customer Support Services
SERVICE MANUAL
Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Cross-Trainer Models CT8500, CT9100, and CT9500HR. Note: Information represents
typical configuration and may differ slightly from actual equipment. The Service Manual provides recommendations for safe and efficient approaches to problem situations. This manual is separated into six sections.
INTRODUCTION THEORY OF OPERATION TERMINOLOGY TABLE OF CONTENTS Section I q TROUBLESHOOTING GUIDES Section II q DIAGNOSTIC TESTS Section III q "How To..." SERVICE AND REPAIR GUIDES Section IV q ELECTRONICS OVERVIEW q WIRING BLOCK DIAGRAMS Section V q PARTS IDENTIFICATION Section VI q MISCELLANEOUS INFORMATION Refer to TABLE OF CONTENTS for section topics. When an operating problem occurs, refer to troubleshooting guides and diagnostic tests in an attempt to isolate the cause. When applicable, guides and tests are listed by symptom followed with suggestions of probable cause(s). Once you have pinpointed the source of the problem, refer to "How To..." guides for recommended repair procedures. "How To..." sub-sections are organized by replaceable part or assembly name. For convenience, sub-section lists recommended Tools Required to complete each specific function. Refer to the PARTS IDENTIFICATION section to identify proper name and number of part to order for repair of equipment. A reproducible telefacsimile order claim form is provided in COMMUNICATING BY TELEFACSIMILE for convenient ordering of service parts. To order, contact Life Fitness Customer Support Services. Via telefacsimile - 24 hrs. /day, 7 days/week. Via telephone - Monday through Friday from 8:00 AM to 7:00 PM ( C.S.T.). To speed Life Fitness Customer Support Services response to your needs, please be prepared to provide the following information to the phone technician. 1. Model number 2. Serial number consists of 3 letters and 6 numbers 3. Symptom of problem 4. Part name and number to order (if known) Before installing a part, review "How To..." and follow the step by step procedures recommended to install the part safely and efficiently. If you have questions or comments, please telephone, FAX or write us. We are:
LIFE FITNESS - CUSTOMER SUPPORT SERVICES 10601 Belmont Avenue; Franklin Park, IL 60131; U.S.A. Telephone: 847.451.0036 or Toll Free 800.351.3737 FAX: 847.288.3702 or Toll Free 800.216.8893
Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers THEORY OF OPERATION
The electronic system on the rear-drive crosstrainer is made up of three main functional blocks: 1) Console, 2) HR telemetry, and 3) Alternator, Power Control Board, and Load. In addition, the 9500 model has Lifepulse contact HR. The following is a description of each functional block: CONSOLE The system voltage (6-7.5Vdc) enters on connector P2 pin 1 and is used to power the LEDs and provide a supply voltage for the 5V-regulator circuitry used to power the microprocessor section. The Keypad entry (users input), Lifepulse (9500HR only), and Telemetry are all processed by the microprocessor. The console outputs a PWM signal to the power control board to control the duty cycle of the load. ALTERNATOR, POWER CONTROL BOARD, AND LOAD Using the PWM signal from the console, the power control board switches the current on and off at the load via Q1. The control board also regulates the alternator voltage using the U1 comparitors. Q3 and Q9 are used to sense the reed switch actuation (autostart feature). POLAR HR telemetry is implemented via a Polar receiver located in the rocker arm shroud at the front of the unit. The Polar receiver connects to the console at connector P7. LIFEPULSE (9500 ONLY) The handlebar electrodes connect to the console board at connector P9. Pins 1 and 4 are signal, pins 2 and 3 are circuit reference.
Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers TERMINOLOGY
The following words and acronyms are commonly referred to throughout this manual. Take time to familiarize yourself with them.
Connectors Display Console Board DSP EEPROM EEROM LDC LED LifePulse PCB Polar Receiver Rear drive RPM
Electrical plugs used to connect wiring into electrical component. Electronic board for making settings and monitoring physical output.
Disgital system processing. Electrically errasible programmable read only memory. Electrically errasible read only memory. Load duty cycle. Light emitting diode used to show a state of operation. Heart rate sensors on hand grips. Power control board regulates voltage to alternator, console, and battery. A device directly in front of the operator that monitors heart rate. The area where all the drive components reside. Revolutions per minute describes the amount of times something turns within a minute of time.
TABLE OF CONTENTS
SECTION I
TROUBLESHOOTING GUIDES PAGE GRINDING, RUBBING, KNOCKING NOISE..................................................................... 2 DRIVE BELT SLIPPING ................................................................................................ 3 UPPER ARMS LOOSE................................................................................................. 3 PLAY IN PEDAL LEVER............................................................................................... 3 NO LOAD .................................................................................................................... 3 NO LEDS ON DISPLAY ................................................................................................ 3 ALTERNATOR BELT SLIPPING..................................................................................... 4 NO HEART RATE OR ERRATIC HEART RATE ............................................................... 4 NO LEDS or RANDOM LEDS LIT................................................................................... 5 NO RPM...................................................................................................................... 5 AUTO START FAILURE ................................................................................................ 5 NOTES........................................................................................................................ 6
SECTION II
DIAGNOSTIC MODES DISPLAY CONSOLES .................................................................................................. 2 ENTERING DIAGNOSTIC STATES 1-17 ......................................................................... 3 DIAGNOSTIC STATE 1: LEDS AND KEYPAD TEST........................................................ 4 DIAGNOSTIC STATE 2: INDIVIDUAL LED TEST.............................................................. 5 DIAGNOSTIC STATE 3: CODE VERSION/RPM/HEART RATE/LDC TESTS....................... 6 DIAGNOSTIC STATE 3: CODE VERSION/RPM/NETWORKING/LDC TESTS (DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 7 DIAGNOSTIC STATE 4: FIELD/ALTERNATOR REGULATOR TEST................................ 8 DIAGNOSTIC STATE 5: PROGRAM VERSION AND NETWORKING TEST ....................... 9 DIAGNOSTIC STATE 5: LIFEPULSE TEST (DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 10 DIAGNOSTIC STATE 6: MAXIMUM WORKOUT DURATION ............................................. 11 DIAGNOSTIC STATE 7: TELEMETRY ON/OFF............................................................... 12 DIAGNOSTIC STATE 8: ENGLISH / METRIC UNITS ........................................................ 13 DIAGNOSTIC STATE 9: POWER SUPPLY TYPE ........................................................... 14 DIAGNOSTIC STATE 10: SHUTDOWN TIME .................................................................. 15 DIAGNOSTIC STATE 11: PROGRAM TIME .................................................................... 16 DIAGNOSTIC STATE 12: STATISTICS............................................................................ 17 DIAGNOSTIC STATE 13: METS ENABLE / DISABLE ...................................................... 18 DIAGNOSTIC STATE 14: KEYPAD SELECTION ............................................................. 19 DIAGNOSTIC STATE 15: TOGGLE ENABLE / DISABLE.................................................. 20 DIAGNOSTIC STATE 16: PHOTOSHOOT....................................................................... 21 DIAGNOSTIC STATE 16: LANQUAGE CONFIGURATION (DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 22 DIAGNOSTIC STATE 17: PHOTOSHOOT (DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 23 NOTES........................................................................................................................ 24
TABLE OF CONTENTS Continued
SECTION III
HOW TO...REPLACE THE: DISPLAY CONSOLE .................................................................................................... 2 ACCESSORY TRAY (OPTIONAL ON CT8500) ................................................................ 3 DISPLAY CONSOLE SUPPORT ASSEMBLY ................................................................. 4 REAR COVERS ........................................................................................................... 5 CRANKARM ROLLER ASSEMBLY AND COVER ........................................................... 6 CRANKARM ASSEMBLY ............................................................................................. 7 DRIVE BELT AND ALTERNATOR BELT......................................................................... 8 POWER CONTROL BOARD ASSEMBLY....................................................................... 9 ALTERNATOR.............................................................................................................. 10 ALTERNATOR BELT..................................................................................................... 11 PEDAL LEVER ASSEMBLY ......................................................................................... 12 ROCKER ARMS........................................................................................................... 13 TIE ROD ...................................................................................................................... 14 CRANKSHAFT PULLEY ASSEMBLY............................................................................. 15 INTERMEDIATE PULLEY.............................................................................................. 16 LOAD RESISTORS....................................................................................................... 17 USER ARMS ............................................................................................................... 18 POLAR RECEIVER ...................................................................................................... 19 MONOCOLUMN COVER............................................................................................... 20 FRAME COVER........................................................................................................... 21 FRONT COVER............................................................................................................ 22 BATTERY .................................................................................................................... 23 REAR WHEELS AND AXLE .......................................................................................... 24 ENDCAPS ................................................................................................................... 25 PEDAL ....................................................................................................................... 26 SET JUMPERS ON CSAFE CARD ................................................................................ 27 NOTES........................................................................................................................ 28
SECTION IV
ELECTRONICS OVERVIEW / WIRING DIAGRAM DISPLAY CONSOLE BOARD........................................................................................ 2 POWER CONTROL BOARD.......................................................................................... 4 ALTERNATOR.............................................................................................................. 5 WIRING BLOCK DIAGRAM ........................................................................................... 6 NOTES........................................................................................................................ 7
TABLE OF CONTENTS Continued
SECTION V
PARTS IDENTIFICATION MODEL IDENTIFICATION and SERIAL NUMBER LOCATION ........................................... 2 CT 8500....................................................................................................................... 3 CT 9100....................................................................................................................... 5 CT 9500 - 15 ................................................................................................................ 7 CT 9500 - 17 ................................................................................................................ 9 NOTES........................................................................................................................ 11
SECTION VI
MISCELLANEOUS INFORMATION PREVENTIVE MAINTENANCE TIPS .............................................................................. 2 INSTALLATION INSTRUCTIONS .................................................................................... 3 UNPACKING INSTRUCTIONS........................................................................................ 9 COMMUNICATING BY FAX........................................................................................... 10 NOTES........................................................................................................................ 12
2000 Life Fitness, a division of Brunswick Corporation. All rights reserved. Life Fitness, Lifecycle, and Lifepulse are registered trademarks, and Heart Rate Zone Training and RELY ON IT are trademarks of Brunswick Corporation. Polar is a registered trademark of Polar Electro, Inc. Any use of these trademarks without the express written consent of Life Fitness or the corresponding companies is forbidden.
M051-00K61-B014 07/00
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
SECTION I
TROUBLESHOOTING GUIDES
Section I
Malfunction
Grinding, rubbing, knocking noises when pedal levers rotate under load.
Probable Cause
Pulleys misaligned.
Corrective Action
Loosen the pillow block bearings, realign the pulleys, and retighten the pillow block bearings. Clean and remove dirt build up. Clean and lubricate with non detergent oil. Reposition rear cover(s) or replace. Check that the inner link cover mounting screws are properly installed.
Dirt build up in pedal tracks. Rear roller wheels frozen.
Link cover contacting rear cover.
Excessive disk wobble.
Make sure no weld interference occurs between the crankarm and the disk cover. Ensure that the crankshaft is flush with the crankarm and check for proper alignment. See How To.
Faulty intermediate shaft assembly. Faulty pillow block. Alternator.
Replace intermediate shaft assy. Replace pillow blocks on crankshaft. Relieve tension on alternator, spin flywheel for smoothness. If thumping occurs, faulty alternator. Replace alternator. Clean all sleeves in the linkage pivot areas and lubricate with non detergent oil. Loosen setscrew and clamping screw in crankarm assembly. Apply blue Loctite (242) on screw threads. Tighten setscrew first to set keyway, then tighten clamping screw. Crankarm bolt requires no Loctite. Replace small extension arm kit. Replace link assembly.
Bearings at pivot points are out of position or dirty.
Setscrews or crankarm bolt in crankarm assembly are loose.
Small extension arm bolt loose. Faulty link bearings. 2
Link mounting loose.
Clean, lubricate, and retighten.
Grinding, rubbing, knocking noises when pedal levers rotate under load.
Excessive end play in rocker arms.
Adjust collars as necessary to take out the end play. See How To Replace Rocker Arms. Align pedal lever. See How To Replace Pedal Lever. See How To Replace Pedal Lever Check belt tension using a J10 belt gauge. The belt deflection should be 1/4 (7mm) at 170 lb for a new belt and 160 lb for an existing belt. Adjust and tighten to a torque of 3035 ft lb. Check for front to back movement in bearings that connect pedal lever to the rocker arm. Replace pedal lever assembly. Replace intermediate shaft assembly. Loosen setscrews and clamping screw in Crankarm Assembly. Apply blue Loctite 242 on screws. Tighten setscrews first and then tighten the clamping screw. Replace link. Clean, lube, and reassemble. Enter diagnostic state 3 and execute the field duty cycle and increase the load. If load does not increase, replace alternator. Using a voltmeter, verify 8Vdc at the 10 position Molex connector pin 1 on the display console PCB. If voltage is present, replace display console. If not, replace power control board.
Pedal lever vibrates or squeaks during operation. Pedal tape not adhering properly. Drive Belt slipping. Loose or worn belt.
Upper Arms feel loose.
Bolts that connect the upper and lower arms are loose. Worn bearings.
Front to back play in pedal lever.
Poly V-Pulley on intermediate shaft is loose. Crankarm loose.
Worn link bearings. Loose link mounting. No Load. Faulty cables, power console board, or alternator.
No LEDs on display.
Faulty display console.
Section I
Malfunction
Probable Cause
Corrective Action
Faulty power control board.
Using a voltmeter, verify 8Vdc at 11 position connector pin 4 on the power control board. If present, replace console cable. If not, replace board.
Malfunction
Alternator belt slipping. No heart rate or erratic heart rate.
Probable Cause
Belt is loose. Pinched cable in Monocolumn cover.
Corrective Action
Retension from 65-70 lb. Remove monocolumn covers and inspect cables. Replace damaged cable. Replace chest strap or reposition it. Reset transmitter. Refer to Diagnostics state 3 to execute the heart rate test. Execute Diagnostic Mode to verify performance of heart rate function. Verify heart-rate cable is properly connected. Using an ohmmeter, verify continuity at the main console cable. Replace user arm/Lifepulse (CT9500HR) Assembly.
Defective chest strap or improperly positioned.
No heart rate reading.
Faulty cable connection.
Malfunctioning user arm/Lifepulse (CT9500HR) Grip Assembly (include worn or damaged heart rate lead). Life Pulse user arm defective.
Verify user arm is functioning. Wipe sensors dry. Using an ohmmeter, verify continuity between Lifepulse sensor and cable connection. Replace if defective. Secure connection. Replace malfunctioning user arm/Lifepulse (CT9500HR) Grip Assembly. Verify that the heart-rate (DSP) board (CT9500HR) is communicating. If defective, replace. Test with known good Display Console. Replace malfunctioning Display Console. Position Cross-Trainer at least 3 ft (1 m) from unit with telemetry or from other electronic devices. Check for corrosion on connectors. Disconnect and reconnect telemetry receiver.
Loose or malfunctioning heart rate lead connection at Display Console.
Heart-rate (DSP) Board (CT9500HR) is faulty or not communicating.
Malfunctioning Display Console.
Cross talk from telemetry and another transmitter or possible interference from other electronic devices. Bad connection.
No LEDs or random LEDs lit.
Cable connection faulty.
Remove display console and verify cable is properly plugged into console. Check for a damaged wire harness. Replace wire harness. Verify cables connections at console to power control PCB, and power control PCB to alternator. Disconnect and reconnect cables. Using a voltmeter, verify cable continuity on console to power control PCB and power control PCB to alternator. Operator must be pedling unit for the auto start feature to activate. Battery voltage should be 5.8 6.3 Vdc. If not, replace the battery. Verify cables connections at console, board, and reed switch are correct and connected properly. Verify that magnet is on crank pulley. If magnet is not present, reinstall magnet. Perform a continuity test. Inspect reed switch for damage. If necessary, replace the board. Replace battery if under 5 VDC and reset jumpers in C-Safe card. See How To Set Jumpers.
Main wire harness damaged.
No RPM. Unit shuts off one minute into program.
Bad cable connection.
Auto start failure
No RPM
Battery
Bad cable connection.
Magnet
Faulty reed switch or board.
Dead battery after C-Safe card is installed.
Section I
Malfunction
Probable Cause
Corrective Action
NOTES:
DIAGNOSTIC MODES
Section II
SECTION II
CT8500, CT9100, and CT9500HR Display Consoles
The following three(3) Display Consoles are representative for each model crosstrainer. The following Diagnostic State pages depict a CT9100 Display Console. Regardless of Display Console, the Message Center always provides current Diagnostic Data.
Level Time RPM Calories
Heart Rate Distance
Cal/Hour Watts Time RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
179
H E AR T R A T E
H E A R T R AT E
153 145
136
1 2 8 119
111
102
85%
Quick Workout Display Lock
145
136
128 119
111
102
85%
Quick Workout
120 1 1 7
80%
114 111 108 105 102 9 9
120
80%
117 114 111 108 105 102
65%
96 93 6 0 %
10 20 30 40 50 6 70 80 90 100 0
AGE
Quick Start:
Press Start Press Quick Workout
Aerobics Mode
Reverse Mode
Start Start Enter Enter
99
65%
96 9 3 60%
1 20 30 40 5 60 7 80 90 100 0 0 0
A G E
Quick Start:
Aerobics Mode
Reverse Mode
Start Enter Enter
Life Fitness USA:1-800-735-3867 Life Fitness Intl.: (+1) 847-288-3300 Life Fitness UK: (+44) (0)1353 666017
Life Fitness USA: 1-800-735-3867 Life Fitness Intl.:(+1) 847-288-3300 Life Fitness UK: (+44) (0)1353 666017
CT9500HR (Display Lock Equipped)
CT9500HR
Level Time RPM Calories
Heart Rate Distance
Cal/Hour Watts
Time RPM
Level Calories
Heart Rate Distance
179 1 7 0
Display Display Lock
Clear Clear
Pause Pause
179 170
Display Lock
Clear Clear
Pause Pause
Quick Workout
H EA R T R A T E
136
HE A RT RA T E
162
153 145
162
153 145
128
119 111
102
85%
Aerobics Aerobics Reverse Mode Mode Mode

80%
Quick Workout
136
128
119 111
102
85%
120 1 1 7
114
1 2 0 117
80%
114 111 108 105 102
111 108
105
102
99
65%
96 93 60%
Start
Quick Start:
Press Start Press Quick Workout AGE
99
65%
96 93 60%
10 20 30 40 50 6 70 80 90 100 0
AGE
10 20 30 40 50 60 70 8 90100 0
Quick Start:
Start
Enter Enter
Life Fitness USA: 1-800-735-3867 Life Fitness Intl.:(+1) 847-288-3300 Life Fitness UK: (+44) (0)1353 666017
Enter Enter
Life Fitness USA:1-800-735-3867 Life Fitness Intl.: (+1) 847-288-3300 Life Fitness UK: (+44) (0)1353 666017
CT9100
CT8500
Section II
170
162
1 2 3 4 5 6 7 8 9 0
Clear Pause
179
170
162 1 5 3
1 2 3 4 5 6 7 8 9 0
Clear Pause
ENTERING DIAGNOSTIC STATES 1-17
To enter the diagnostic mode, proceed as follows: 1. Press down and hold the DOWN ARROW key. While doing this, press the CLEAR (CT9100) or CLEAR/PAUSE (CT9500) key twice within 2.5 seconds. The console will go blank momentarily, but do not release the DOWN ARROW key. As soon as the MESSAGE CENTER displays the word DIAGNOSTICS, then release the DOWN ARROW key. Press the ENTER key to scroll through diagnostic states 1-17. Press the UP and DOWN ARROW keys to activate a selection within a diagnostic state. Press the CLEAR key to scroll back to a previous diagnostic state Press the CLEAR key as required to exit out of the diagnostic program. For diagnostic states that have a subdirectory, press the DISPLAY LOCK key to enter.
NOTE: RPM diagnostic mode requires pedaling. NOTE: Factory defaults are displayed when the LED is illuminated on the ENTER key.
Section II
2. 3. 4. 5. 6.
DIAGNOSTIC STATE 1 - LEDs and KEYPAD TEST
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
248
HE AR T R ATE
Message Center
179 170 162 153145 136 128 119 111 102 85% 120 117 114 111 108105 102

Aerobics Mode
Clear Clear
Pause Pause
Reverse Quick Mode Workout
80%
99
96
65%
9 3 60%
10 20 30 40 50 60 7 0 80 90 100
Start
Quick Start:
AGE
CAUTION: CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT. STOP EXERCISING IF YOU FEEL PAIN, FAINT, DIZZY OR SHORT OF BREATH ATTENTION : CONSULTEZ UN MDECIN AVANT DUTILISER CET APPAREIL. ARRTEZVOUS SI VOUS AVEZ DES DOULEURS, SI VOUS VOUS SENTEZ FAIBLE, TOURDI OU COURT DE SOUFFLE.
Life Fitness USA:1-800-735-3867 Life Fitness Intl.: (+1) 847-288-3300
Enter Enter
Profile Window
Initially all LEDs are lit. When pressing the keys listed below, the appropriate character should display across the MESSAGE CENTER.
CROSS-TRAINERS 8500 AND 9100

KEY MODE DEPRESSED Display Lock Clear Pause Aerobics Mode Reverse Mode Quick Workout Up Arrow Down Arrow Start Enter CHARACTER DISPLAYED L P A R Q U D -
CROSS-TRAINER 9500
KEY MODE DEPRESSED Clear Pause Quick Workout Aerobics Mode Reverse Mode Up Arrow Down Arrow Numeric Keys 0-9 Start Enter CHARACTER DISPLAYED Q A R U D Numeric Value -
Press the CLEAR key to exit diagnostic mode. Press the ENTER key to advance to Diagnostic State 2.
DIAGNOSTIC STATE 2 - INDIVIDUAL LED TEST
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
128 119111 102 85%
Aerobics Reverse Quick Aerobics Mode Mode Workout Mode
120117 114 111108 105
80%
102
99 96
65%
9 3 60%
Start
Quick Start:
10 20 30 40 50 60 70 80 90 100
AGE
Life Fitness USA: 1-800-735-3867 Life Fitness Intl.: (+1) 847-288-3300
Enter Enter
In this test, the system scrolls through each LED automatically to test its functionality. Press the CLEAR key to return to Diagnostics State 1. Press the ENTER key to advance to Diagnostics State 3.
Section II
HEAR T RATE
179170 162 153 145 136
Clear Clear
Pause Pause
DIAGNOSTIC STATE 3 - Code Version and RPM, Heart Rate, and LDC Tests
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
PX.XX

HR
0
Display Lock
HEAR T RATE
179170 162 153 145 136 128 119 111 102 85% 120117 114 111108 105 102
Clear Clear
Reverse Mode
Pause Pause
Quick Workout
Aerobics Aerobics Mode Mode
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
The items displayed for selection are Code Version, RPM, Heart Rate, and Load Duty Cycle (LDC). Code Version will be displayed under the TIME segment and will be a four(4) digit number. Press the DISPLAY LOCK key or the 8 key (CT9500) to access software part number xxxx-xxxxx-xxxx. To go back to the original diagnostic screen press the DISPLAY LOCK key or the 8 key (CT9500). To verify the RPM signal, pedal and observe RPM value. To verify that the heart rate system is functioning properly, use a polar simulator or a chest strap. If the unit functions correctly the Heart Rate LED will illuminate and a heart rate value will be displayed in the MESSAGE CENTER under the LEVEL and CALORIES segment. Otherwise if heart rate is not detected then the HR characters will be displayed and the HEART RATE LED will not be lit. While pedaling, press the ARROW keys to verify the alternator LOAD DUTY CYCLE. Using the UP ARROW, increase load resistance from 0 to 250. Zero (0) equals a no Load Duty Cycle (LDC) state. 250 equals 100% of LDC. The Load Duty Cycle value will be located under the HEART RATE and DISTANCE segment. NOTE: Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10% (CT9100/8500 feature). Use 4 and 6 KEYS to increment and decrement LDC value by 10% (CT9500 feature). Press the CLEAR key to return to Diagnostics State 2. Press the ENTER key to advance to Diagnostics State 4.
DIAGNOSTIC STATE 3 - Code Version and RPM, Networking, and LDC Tests
(DISPLAY LOCK EQUIPPED MODEL ONLY)
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
179
170
HEART R ATE
162 153
145 136
128
119
111 102
85%
120 117
80%
114 111 108 105 102
99
65%
96 93 60%
10 20 30 40 50 60 7 80 90 100 0
AGE
Quick Start:
Aerobics Mode
1 2 3 4 5 6 7 8 9 0
Reverse Mode
Start Enter Enter
Life Fitness USA: 1-800-735-3867 Life Fitness Intl.: (+1) 847-288-3300 Life Fitness UK: (+44) (0)1353 666017
The items displayed for selection are Code Version, RPM, Networking, and Load Duty Cycle (LDC). Code Version will be displayed under the TIME segment and will be a four(4) digit number. Press the DISPLAY LOCK key or the 8 key (CT9500) to access software part number xxxx-xxxxx-xxxx. To go back to the original diagnostic screen press the DISPLAY LOCK key or the 8 key (CT9500). To verify the RPM signal, pedal and observe RPM value. While pedaling, press the ARROW keys to verify the alternator LOAD DUTY CYCLE. Using the UP ARROW, increase load resistance from 0 to 250. Zero (0) equals a no Load Duty Cycle (LDC) state. 250 equals 100% of LDC. The Load Duty Cycle value will be located under the HEART RATE and DISTANCE segment. The status of the LIFELINK board and LIFECENTER connection will be displayed in the CALORIES window. The following message will be displayed: NONE = No LIFELINK board detected NULL = Board detected but not communicating ON = Online status with Life Center OFF = Offline status with Life Center NOTE: Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10% (CT9100/8500 feature). Press the CLEAR key to return to Diagnostics State 2. Press the ENTER key to advance to Diagnostics State 4. 7
Section II
Clear Pause
DIAGNOSTIC STATE 4 - FIELD/ALTERNATOR-REGULATOR TEST
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
FIELD/ALTREG TST

HEART RATE
179170 162153 145136

Clear Clear
Reverse Mode
Pause Pause
Quick Workout
128 119111 102 85%
120 117114 111108 105102
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
Prior to enter the test modes, set the field load duty in diagnostics state 3 to 50. Press the Display Lock key, or the number 2 key for CT9500 only, once to access Field Test. Use the UP/DOWN ARROW toggle the field voltage ON and OFF. This will verify the operation of the alternator and cable connections. The resistance should increase as the field test is turned on. Press the Display Lock key, or the number 2 key for CT9500 only, again to access the Alternator/Regulator Test. Use the UP/DOWN ARROW key to toggle voltage ON/OFF. This will verify that the power control board is regulating the voltage properly and the load resistance should slightly decrease as the alternator/regulator is turned on. Press the CLEAR key to return to Diagnostics State 3. Press the ENTER key to advance to Diagnostics State 5.
DIAGNOSTIC STATE 5 - PROGRAM VERSION AND NETWORKING TEST
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
PX.XX

PX.XX
NONE
Section II
HEART RATE
179170 162153 145136
Clear Clear
Reverse Mode
Pause Pause
Quick Workout
128 119111 102 85%
120 117114 111108 105102
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
The PROGRAM VERSION NUMBER for 68HC05 micro controller code version will be displayed in the elapsed time window (e.g. P_. _0). The PROGRAM VERSION NUMBER for HEART RATE DSP Board will be displayed in the speed window (eg. P_. _0). The status of the LIFELINK board and LIFECENTER connection will be displayed in the CALORIES window. The following message will be displayed: NONE = No LIFELINK board detected NULL = Board detected but not communicating ON = Online status with Life Center OFF = Offline status with Life Center Press the CLEAR key to return to Diagnostics State 4. Press the ENTER key to advance to Diagnostics State 6.
10
DIAGNOSTIC STATE 5 LIFEPULSE TEST

Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
179 170
H E A R T R AT E
162 153 145
136
128 119
111 102
85%
120 117
80%
114 111 108 105 102 99
65%
96 93 60%
10 20 3 40 50 6 70 8 90100 0 0 0
AGE
Quick Start:
Aerobics Mode
1 2 3 4 5 6 7 8 9 0
Clear Pause
Reverse Mode
Start Enter Enter
Upon initial entry to this test, a message concerning the configuration of the lifepulse system being On or Off. This test will allow the user to test the lifepulse heart rate system. Following this message, the lifepulse system can be manually tested. A heart will be in the profile window. The system will show when the user has placed their hands on the lifepulse sensors. When the left sensor detects hands on condition, a L will be placed in the profile window with the heart. When the right sensor detects hands on condition, a R will be placed in the profile window with the heart. A timer will start counting from the time when a both left and right hands on condition occurs to when the lifepulse system can reliable give the user their heart rate. This timer will stop when the heart rate is given. The gain value of the heart rate signal is shown. The confidence level of the heart rate value is displayed. The value ranges from 0 to 9. A value of 9 is considered to be high confidence. A value of 0 is considered to be low confidence. Press the CLEAR key to return to Diagnostics State 4. Press the ENTER key to advance to Diagnostics State 6.
11
DIAGNOSTIC STATE 6 - MAXIMUM WORKOUT DURATION
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
MAX DURATION 60

HE AR T RAT E
179170 162 153 145 136

Clear Clear
Pause Pause
128119 111 102 85%
Reverse Quick Mode Workout
120 117114 111108 105
80%
102
99 96
65%
93 60%
Start
Quick Start:
10 20 30 40 50 60 70 80 90 100
AGE
Enter Enter
Maximum program duration can be adjusted from a range between 60-99 minutes. Press the DOWN ARROW to decrease values in decrements of 1 minute. Press the UP ARROW key to increase values in increments of 1 minute. The LED on the ENTER key will illuminate when the value is set to the default of 60 minutes. This value is stored in EEPROM and is stored when the cross-trainer is not in use.
Press the CLEAR key to return to Diagnostics State 5. Press the ENTER key to advance to Diagnostics State 7.
12
Section II
DIAGNOSTIC STATE 7 - TELEMETRY ON/OFF
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
TELEMETRY ON

HEART R ATE
179170 162 153145 136128 119 111 10285% 120 117114 111108 105 102 99
Clear Clear
Pause Pause
Quick Workout
Aerobics Reverse Aerobics Mode Mode Mode
80% 65%
96 93 60%
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
The default is TELEMETRY ON (CT91/95) TELEMETRY OFF (CT85). Press the DOWN ARROW to turn OFF telemetry and the UP ARROW to turn it back ON. A heart shape illuminates in the program profile window. The ENTER key LED illuminates to indicate when TELEMETRY ON. This value is stored in EEROM while the crosstrainer is not in use. Press the CLEAR key to return to Diagnostic State 6. Press the ENTER key to advance to Diagnostic State 8.
13
DIAGNOSTIC STATE 8 - ENGLISH OR METRIC UNITS
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
ENGLISH UNITS

HEART RATE
179170 162153 145136
128 119111 102 85%
Reverse Mode
Quick Workout
120 117114 111108 105102
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
ENGLISH or METRIC units can be selected. Press the DOWN ARROW to select METRIC units. Press the UP ARROW to select ENGLISH. The ENTER key LED illuminates when defaulted to ENGLISH UNITS. This value is stored in EEROM and is kept when the cross-trainer is not in use.
Press the CLEAR key to return to Diagnostic State 7 Press the ENTER key to advance to Diagnostic State 9
14
Section II
Clear Clear
Pause Pause
DIAGNOSTIC STATE 9 - POWER SUPPLY TYPE
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
BATTERY

HEART RATE
179170 162153 145136

Clear Clear
Reverse Mode
Pause Pause
Quick Workout
128 119111 102 85%
120 117114 111108 105102
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
There are two types of power supply sources (BATTERY and EXTERNAL). Make sure that the displayed value is BATTERY. If need be, change the value to BATTERY by pressing the UP ARROW key. NOTE: If external power is turned ON, the 6 volt rechargeable battery will be drained. Press the CLEAR key to return to Diagnostic State 8. Press the ENTER key to advance to Diagnostic State 10.
15
DIAGNOSTIC STATE 10 - SHUTDOWN TIME
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
SHUTDOWN TIME 60
179170 162153 145136

Clear Clear
Reverse Mode
Pause Pause
Quick Workout
HEART RATE
128 119111 102 85%
120 117114 111108 105102
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
If BATTERY is selected, then SHUTDOWN TIME must be set. The SHUTDOWN TIME (BATTERY only) is set in seconds from 1 to 60. The time specified will shut off the Cross-Trainer when no RPMs are detected. Pressing the CLEAR/PAUSE key will return to Diagnostics State 9. Pressing the ENTER key will advance to Diagnostics State 11.
16
Section II
DIAGNOSTIC STATE 11 - PROGRAM TIME
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
PROGRAM TIME 60

HEART R ATE
179170 162 153145 136128 119 111 10285% 120 117114 111108 105 102 99
Clear Clear
Pause Pause
Quick Workout
Aerobics Reverse Aerobics Mode Mode Mode
80% 65%
96 93 60%
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
The PROGRAM TIME, is the maximum time allowed for inputting weight, age, etc. If no entry to program is made after the set program time from 60-99 seconds, the unit automatically shuts off. NOTE: If no keys are pressed, the unit will shut down after 15 seconds, not 60-99. Pressing the CLEAR/PAUSE key will return to Diagnostics State 10. Pressing the ENTER key will advance to Diagnostics State 12.
17
DIAGNOSTIC STATE 12 STATISTICS
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
STATISTICS

HEAR T RATE
179170 162 153 145 136 128 119 111 102 85% 120117 114 111108 105 102
Display Lock
Clear Clear
Reverse Mode
Pause Pause
Quick Workout
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
Press the UP ARROW to scroll forward through the programs for number of times each program has been selected. Press the DOWN ARROW to scroll backwards through the programs to display total hours. Press the CLEAR key to return to Diagnostic State 11. Press the ENTER key to advance to Diagnostic State 13. STATISTICS HOURS HILL RANDOM MANUAL FAT CARDIO X-REV X-AERO QUICK HR-WIPE Number of hours Number of times Number of times Number of times Number of times Number of times Number of times Number of times Number of times Number of times wiping of hand sensor message
18
Section II
DIAGNOSTIC STATE 13 - METS ENABLE/DISABLE
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
METS OFF

HEAR T RATE
179170 162 153 145 136 128 119 111 102 85% 120117 114 111108 105 102
Display Lock
Clear Clear
Reverse Mode
Pause Pause
Quick Workout
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
Press the DOWN ARROW to disable the METS mode. Press the UP ARROW to enable the METS mode. METS is the expression of the rate of work (power output). One MET is approximately equal to a persons metabolism when seated and relaxed. When the value is set to METS OFF default the ENTER key LED will illuminate. This value is stored in EEPROM and is stored when the cross-trainer is not in use. Press the CLEAR key to return to Diagnostic State 12. Press the ENTER key to advance to Diagnostic State 14.
19
DIAGNOSTIC STATE 14 - KEYPAD SELECTION
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
CT91/55 K-PAD ON

HEAR T RATE
179170 162 153 145 136 128 119 111 102 85% 120117 114 111108 105 102
Display Lock
Clear Clear
Reverse Mode
Pause Pause
Quick Workout
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
To select the appropriate keypad press the UP/DOWN ARROW keys for the designated model. Make sure that the system displays CT9500 K-PAD ON, CT91/55 K-PAD ON or CT8500 K-PAD ON depending machine model. Press the CLEAR key to return to Diagnostic State 13. Press the ENTER key to advance to Diagnostic State 15.
20
Section II
DIAGNOSTIC STATE 15 - TOGGLE ENABLE/DISABLE
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
TOGGLED DISABLED

HEART RATE
179170 162153 145136

Clear Clear
Reverse Mode
Pause Pause
Quick Workout
128 119111 102 85%
120 117114 111108 105102
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
To select the appropriate default press the UP/DOWN ARROW keys until the message TOGGLE DISABLED, WATTS TOGGLE ON, CAL/HR TOGGLE ON, or CAL/HR WTTS TGGL is displayed. These are different options the customer can select to have the display console toggle from one item to another. Press the CLEAR key to return to Diagnostic State 14. Press the ENTER key to advance to Diagnostic State 16.
21
DIAGNOSTIC STATE 16 PHOTOSHOOT
Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
28:45

52
372
135
Display Lock
HEAR T RATE
179170 162 153 145 136 128 119 111 102 85% 120117 114 111108 105 102
Clear Clear
Reverse Mode
Pause Pause
Quick Workout
80% 65%
96 93 60%
99
10 20 30 40 50 60 70 80 90 100
Start
Quick Start:
AGE
Enter Enter
Display values that have no significance and are used strictly for photographic sessions to assimilate values in the display console. Press the CLEAR key to return to Diagnostic State 15 or continue to press the CLEAR key to exit diagnostics.
22
Section II
DIAGNOSTIC STATE 16 LANGUAGE CONFIGURATION

Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
179
170
HEA RT RATE
162 153
145 136
128
119 111
102
85%
120 117
80%
114 111 108 105 102 99
65%
96 93 60%
10 2 30 4 50 60 7 80 9 100 0 0 0 0
AGE
Quick Start:
Aerobics Mode
1 2 3 4 5 6 7 8 9 0
Clear Pause
Reverse Mode
Start Enter Enter
This test allows the user to select a language for the unit. Upon initial entry to this test, a message concerning the current configuration of the language is displayed. Following this message, the user can change the language by pressing the arrow key to scroll through the available list of language in the product. After the language has been selected, pressing Clear or Enter keys will cause the product to save the language selected.
23
DIAGNOSTIC STATE 17 PHOTOSHOOT

Time
RPM
Level Calories
Heart Rate Distance
Cal/Hour Watts
28:45 52
372
135
1 2 3 4 5 6 7 8 9 0
Clear Pause
179
170
H EA RT RA T E
162 153
145 136
128
119 111
102
85%
120 117
80%
114 111 108 105 102
99
65%
96 93 60%
10 20 30 40 50 60 70 8 90 100 0
AGE
Quick Start:
Aerobics Mode
Reverse Mode
Start Enter Enter
Display values that have no significance and are used strictly for photographic sessions to assimilate values in the display console. Press the CLEAR key to return to Diagnostic State 16 or continue to press the CLEAR key to exit diagnostics.
24
Section II
NOTES:
25
SECTION III
How To... SERVICE AND REPAIR GUIDE

Section III
1
How To... Replace the Display Console

Tools required: Phillips screwdriver 1. Remove the MOUNTING SCREWS(4) from under the CONSOLE. Lift the console up enough to disconnect the 10-Pin and 3 or 4-Pin connectors.
Accessory Tray
3-Pin Connector
Console Spacer
2.
3.
Remove the console and spacer from the console post or if equipped, the accessory tray which is standard on CT95/91 and optional on CT85. Install new console in reverse order.
(Optional on CT85 only)
10-Pin Connector
4.
Display Console Screws(4)
4-Pin Connector (9500 only)
Console Support Assembly
How To... Replace the Accessory Tray (Optional on CT8500)

Tools required: Phillips screwdriver, Allen wrench set, and 3/8 Standard wrench set 1. Remove the MOUNTING SCREWS(4) from under the CONSOLE. Lift the console up enough to disconnect the 10-Pin, 3-Pin or 4-Pin connectors. Remove the console and spacer from the accessory tray. Remove the ACCESSORY TRAY BOLTS(4) and NUTS(4), and lift off the ACCESSORY TRAY from the console post. Install new accessory tray in reverse order.
3-Pin Connector 10-Pin Connector Wire Harness Accessory Tray Nuts(4) Display Console Screws(4)
Accessory Tray Console Spacer Accessory Tray Screws(4) 4-Pin Connector (9500 only)
2.
3.
4.
5.
Section III
Console Support Assembly
How To... Replace the Display Console Support Assembly

Tools required: Phillips screwdriver and Allen wrench set
Rocker Cover and Screws(3)
Polar Receiver Monocolumn Cover Foam Insulator Monocolumn Cover Monocolumn Cover Screws(4)
Back Rocker Cover
Polar Receiver Foam Insulator Monocolumn Cover Monocolumn Cover Monocolumn Cover Screws(2)
Model 8500/9100 Shown
Model 9500HR Shown
Front Rocker Cover
Front Rocker Cover and Screws(3)
1. 2.
Remove the console and accessory tray. See How To. Remove the MONOCOLUMN COVER (ALL MODELS) and ROCKER ARM COVERS (9500). Remove the POLAR RECEIVER. Remove the two(2) HEX HEAD CAPSCREWS and FLAT WASHERS securing the CONSOLE SUPPORT ASSEMBLY. Lift the CONSOLE POST out of the MONOCOLUMN while guiding the wire harness out. Install new console support in reverse order.
Display Console Screws(4) 10-Pin Connector Spacer Accessory Tray Screws(4)
3-Pin Connector
Accessory Tray
Console
3. 4.
Accessory Tray Nuts(4)
5.
6.
4-Pin Connector (Model 9500)
Hex Bolts(2)
Console Support Assembly Wire Harness
Flat Washers(2)
Monocolumn
How To... Replace The Rear Covers

Tools required: Phillips magnetic screwdriver #2, Allen wrench set, 3/8 Socket set, and Standard wrench set 1. Remove the OUTER LINK COVER by removing six(6) mounting screws from each OUTER LINK COVER. Remove the ANTI-LIFT BRACKET by removing two(2) mounting bolts from each bracket. Remove the clevis cover from each pedal lever. Remove the PEDAL LEVER by removing the mounting bolt and nut at each ROCKER ARM joint and the hex bolt fom each ARM EXTENSION. Remove the PLUG from the LEFT and RIGHT COVERS. Remove the REAR COVER by removing three(3) screws from the LEFT REAR COVER then seven(7) screws from the RIGHT REAR COVER. Install rear covers in reverse order. Make sure that each pedal lever roller guide is centered over the roller. If not, lossen the pedal lever assembly mounting bolt and recenter the pedal lever so that it is centered on the roller, then retighten the
Left Rear Cover Right Rear Cover
Rocker Arms Rear Cover RH
Pedal Lever Nuts(2) Torque 30-35 FT. LBS.
Bolt
2.
Rear Cover LH
Plug
Bolt Clevis Covers
3.
Pedal Lever RH
4.
5.
6.
7.
Plug
Pedal Lever Assembly Pedal Lever Roller Guide
mounting bolt.
Crankarm Shaft YES

Correct Position of the Roller
NO
Incorrect Position of the Roller
Roller
END VIEW OF PEDAL LEVER
Section III
Arm Extension Hex Bolt
Anti-Lift Bracket Anti-Lift Bolts(2) Torque 30-35 FT. LBS.
Cover Screws(6) Torque 6-10 IN. LBS. Outer Link Cover RH
How To... Replace The Crankarm Roller Assembly and Cover

Tools required: Snap ring pliers and Allen wrench set, and Phillips screwdriver 1. 2. Remove the REAR COVERS. See How To Remove Rear Covers. Remove the ALLEN-HEAD CAPSCREW from the end ot the ARM EXTENSION. Remove the SNAP RING, TAB WASHER and ROLLER BEARING ASSEMBLY on Old configuration assembly. For New configuration assembly, remove the setscrew and collar, then remove the roller bearing assembly. Remove the two(2) countersunk screws securing the crankarm cover to the crankarm, and remove the CRANKARM COVER. Install the CRANKARM COVER and ROLLER BEARING in the reverse order. For new style roller bearing assemblies, make sure that a maximum of .005" clearance is maintained between the ROLLER BEARING and the COLLAR.
Tab Washer Screws(2) Torque 65-75 in lbs Allen-head Cap screw Torque 30-35 ft lbs
Crankarm Cover Roller Bearing Assembly
3.
Snap Ring
Arm Extension
4.
5.
Old Style
Crankarm Cover Roller Assembly MUST Turn Freely After Assembly
Crank Cover
Roller Bearing Assembly
Collar
.005 MAX Clearance Arm Extension
Torque 30-35 ft lbs Arm Extension Torque 28-33 in lbs (2 places) Collar NEW STYLE
How To... Replace The Crankarm Assembly

Tools required: Snap ring pliers and Allen wrench set, and Phillips screwdriver 1. Remove the REAR COVERS. See How To Remove Rear Covers. Remove the ALLEN-HEAD CAPSCREW from the end ot the ARM EXTENSION. Remove the SNAP RING, TAB WASHER and ROLLER BEARING ASSEMBLY on Old configuration assembly. For New configuration assembly, remove the SETSCREW and COLLAR, then remove the roller bearing assembly. Remove the two(2) countersunk screws securing the crankarm cover to the crankarm, and remove the CRANKARM COVER. Remove the NUT and BOLT from the CRANKARM. Remove the SETSCREW and KEY from the CRANKARM. Remove the CRANKARM off the shaft.
Collar Crankarm Cover Roller Assembly MUST Turn Freely After Assembly .005 MAX Clearance Arm Extension
Crankarm Cover Roller Bearing Assembly
2.
3.
Snap Ring
Arm Extension
Tab Washer Screws(2) Torque 65-75 in lbs
4.
Allen-head Cap screw Torque 30-35 ft lbs
Old Style
5. 6.
Crank Cover
7. 8.
Install the CRANKARM COVER and ROLLER BEARING in the reverse order. For new style roller bearing assemblies, make sure that a maximum of .005" clearance is maintained between the ROLLER BEARING and the COLLAR.
Torque 30-35 ft lbs Arm Extension Torque 28-33 in lbs (2 places) Collar NEW STYLE
Crankarm Cover Crankarm Nut Crankarm Assembly
Crankarm Bolt Crankarm Setscrew BACKSIDE VIEW Key
Arm Extension
Section III
Roller Bearing Assembly
How To... Replace The Drive Belt and Alternator Belt

Tools required: 3/8 Socket set and Standard wrench set, and Phillips screwdriver
Alternator Belt New: 75-85 lbs Used: 60 lbs Main Drive Belt New: 170 lbs Used: 160 lbs Pivot Bolt Torque 50-60 ft lbs Mounting Bolt Torque 18-20 ft lbs Crankshaft Pulley Assembly
Intermediate Pulley
Alternator Support Bracket Torque 30-35 ft lbs
Pillow Bock Bearing Nuts Torque 30-35 ft lbs
1. 2.
Remove the both REAR COVERS. See How ToRemove Rear Covers. Loosen the ALTERNATOR PIVOT BOLT and release tension on the alternator belt, then remove the ALTERNATOR BELT off the INTERMEDIATE PULLEY. Loosen the five(5) mounting bolts on the ALTERNATOR BRACKET and move the bracket upward and remove the DRIVE BELT off the crankshaft pulley assembly. Remove the CRANKSHAFT PULLEY ASSEMBLY by removing four(4) mounting bolts at the PILLOW BLOCK BEARINGS. Remove and discard the DRIVE BELT. Install new drive belt and alternator belt in reverse order.
3.
4.
5. 6.
How To...Remove Power Control Board Assembly

Tools Required: Slotted head screwdriver and Phillips screwdriver 1. Remove the right REAR COVER. See How ToRemove Rear Covers. Disconnect the 12 and 11-Pin Connectors on the PCB. Remove the PCB from its mounting bracket. Install new PCB in reverse order.
2. 3. 4.
PCB Mounting Bracket
PCB Torque 33-37 in lbs
Power Control Board Bracket
Power Control Board
Torque 8-10 IN LBS
Spacers(4)
Section III
How To...Replace Alternator

Tools Required: 3/8 Socket set and Standard wrench set, and Phillips screwdriver 1. Remove the REAR COVERS. See How ToRemove Rear Covers. Disconnect the ALTERNATOR WIRING HARNESS from the alternator. Remove the ALTERNATOR PIVOT BOLT and MOUNTING BOLT, then lift out the alternator. Install new alternator in reverse order.
Alternator Mounting Bolt Torque 18-20 ft lbs Alternator Pivot Bolt
2.
3.
Alternator Belt
4.
Nut Torque 50-60 ft lbs
Alternator
Pivot Bolt
Alternator Belt New: 85 ft lbs Used: 60 ft lbs Intermediate Pulley Mounting Bolt Torque 18-20 ft lbs Main Drive Belt New: 170 ft lbs Used: 160 ft lbs
10
How To...Replace Alternator Belt

Tools Required: 3/8 Socket set and Standard wrench set, and Phillips screwdriver
1.
Remove the REAR COVERS. See How ToRemove Rear Covers. Loosen the ALTERNATOR PIVOT BOLT and its MOUNTING BOLT. Rotate the alternator down to release belt tension, then remove the ALTERNATOR BELT. Install new alternator belt in reverse order.
Alternator Belt New: 85 ft lbs Used: 60 ft lbs Rotate Down Alternator Pivot Bolt
2.
Alternator Mounting Bolt
3.
4.
11
Section III
How To... Replace Pedal Lever Assembly

Tools required: Phillip screwdriver, Allen wrench set, 3/8 Socket set, and Standard wrench set 1. Remove six(6) screws from the OUTER LINK COVER and remove cover. Remove the TIE ROD. Remove the CLEVIS COVER from each pedal lever. Remove the ANTI-LIFT BRACKET and lower the PEDAL LEVER ASSEMBLY. Remove the nut and bolt securing the pedal lever to the ROCKER ARM, and remove the pedal lever. Remove the inner link cover screws(4) and remove the inner link cover. Install new pedal lever in reverse order except as follow: A) When tightening the clevis to the pedal lever bolt, the pedal lever track must be resting on the roller on the crankarm. See illustrastion below. B) The identificaion mark on the tie rod must be forward. C) An identification mark on the tie rod must face towards the front of the machine. Using a small amount of Moly grease between the inner race of the bearing and sleeve, attach the tie rod at the rear of the machine first, then at the front. D) Use a small amount of grease between the spherical washer and the spherical end sleeve.
Spherical Washer Spherical End Sleeve 3-Turn Wave Spring Thrust Washer Flat Washer Linkage Nuts(2) Torque 18-20 FT. LBS.
Bolts(2) Anti-Lift Bracket Anti-Lift Bolts(2) Torque 30-35 FT. LBS. Cover Screws(6) Torque 6-10 IN. LBS. Outer Link Cover Rear Cover RH Rocker Arms Pedal Lever Nuts(2) Torque 30-35 FT. LBS. Clevis Covers
2. 3.
Bolts(2)
4.
5.
Pedal Lever RH
6.
7.
Tie Rod (Front end)
Front End View
Tie Rod (Back end) Shoulder Sleeve 3-Turn Wave Spring

Pedal Lever Assembly Pedal Lever Roller Guide
Linkage Nuts(2) Torque 18-20 FT. LBS. Thrust Washer Flat Washer Back End View
Crankarm Shaft YES

Correct Position of the Roller
NO
Incorrect Position of the Roller
Roller
END VIEW OF PEDAL LEVER
12
How To... Replace Rocker Arms

Tools required: 3/8 Socket set and Standard wrench set 1. Remove the UPPER ARMS. See How ToReplace User Arms. Remove the MONOCOLUMN COVERS and CLEVIS COVERS. Remove the clevis cover from each pedal lever. Remove the nut and bolt securing the PEDAL LEVER to the ROCKER ARM, and lower the pedal lever.
Pedal Lever
End Cap Torque 30-35 FT. LBS. Bolts(2)
2.
3. 4.
5. 6.
Remove the END CAP from the rocker arm. Remove bolt and washer and slide-off the rocker arm. Install new rocker arm in reverse order.
Clevis Covers
7. 8.
Units with split collar design, make sure to position to within .005" gap of rocker arm. Units with one-piece collars, make sure collar is positioned against shaft shoulder.
Rocker Arm Shaft Shoulder One-Piece Collar
Rocker Arm
Torque 30-35 ft lbs Flat Washer
Shaft
Split Collar
Torque 30-35 ft lbs Flat Washer
Flat Washer Torque 30-35 ft lbs
Rocker Arm
Flat Washer Torque 30-35 ft lbs
Rocker Arm
Rocker Arm
Rocker Arm
13
Section III
How To... Replace Tie Rod

Tools required: Phillips magnetic screwdriver #2 and 3/8 Socket set 1. Remove the OUTER LINK COVER by removing the six(6) mounting screws. Remove the TIE ROD NUT from the ARM EXTENSION and PEDAL ARM. Discard the tie rod and hardware. Install new TIE ROD in reverse order.
Clevis Covers
2.
3. 4.
NOTE: An identification mark on the tie rod must face towards the front of the machine. Using a small amount of Moly grease between the inner race of the bearing and sleeve, attach the tie rod at the rear of the machine first, then at the front.
Bolts(2) Cover Screws(6) Torque 6-10 IN. LBS. Outer Link Cover
Spherical Washer Spherical End Sleeve 3-Turn Wave Spring Thrust Washer Flat Washer Linkage Nuts(2) Torque 18-20 FT. LBS.
Tie Rod (Front end)
Front End View
Tie Rod (Back end) Shoulder Sleeve 3-Turn Wave Spring Thrust Washer Flat Washer Back End View Linkage Nuts(2) Torque 18-20 FT. LBS.
14
How To... Replace Crankshaft Pulley Assembly

Tools required: Allen wrench set, 3/8 Socket set, and Standard wrench set 1. Remove the REAR COVERS. See How ToRemove Rear Covers. See How ToRemove Alternator Belt. Loosen six(6) mounting bolts on the ALTERNATOR SUPPORT BRACKET. Push this bracket up to remove tension on the DRIVE BELT, and remove the drive belt. Remove four(4) bolts from the CRANKSHAFT PULLEY ASSEMBLY by removing four(4) mounting bolts at the PILLOW BLOCK BEARINGS. Replace components on the crankshaft pulley assembly as necessary. Install new crankshaft pulley in reverse order.
Pillow Block Bearing Crankshaft Plate Washer Crankshaft Pulley
2.
Crankshaft w/Plate
Snap Ring
Pillow Block Bearing Snap Ring
3.
Bolts(4)
4.
Torque 10-12 FT LBS
5.
Crankshaft Pulley
6.
Pillow Block Bearing Pillow Block Bearing Bolts
Pillow Block Bearing Nuts and Washers Torque 30-35 ft lbs
15
Section III
Main Drive Belt New: 170 ft lbs Used: 160 ft lbs
How To... Replace The Intermediate Pulley

Tools required: 3/8 Socket set and Standard wrench set 1. Remove the REAR COVERS. See How ToRemove Rear Covers. Loosen the ALTERNATOR PIVOT BOLT and rotate the alternator down to relieve belt tension. Loosen the belt tension on the INTERMEDIATE PULLEY by loosening the five(5) bolts on the ALTERNATOR MOUNTING BRACKET. Remove the INTERMEDIATE SHAFT BOLTand the INTERMEDIATE PULLEY. Install new INTERMEDIATE PULLEY in reverse order.
Alternator Pivot Bolt Torque 50-60 ft lbs
Alternator Bracket Bolt Rotate Down Drive Belt Alternator Pivot Bolt
2.
3.
Alternator Belt
4.
Alternator Mounting Bracket
5.
Intermediate Shaft Bolt
Alternator Belt New: 85 ft lbs Used: 60 ft lbs
Intermediate Pulley
Alternator Bracket Torque 30-35 ft lbs
Main Drive Belt New: 170 ft lbs Used: 160 ft lbs
16
How To... Replace Load Resistors

Tools required: Slotted screwdriver 1. Remove the right REAR COVER. See How ToRemove Rear Covers. Disconnect wires at the LOAD RESISTORS. Remove the LOAD RESISTORS by removing two(2) hex-head screws securing the load resistor to the frame. Install new load resistors in reverse order.
2.
3.
4.
Load Resistors
Load Resistor Bracket and Screws Torque 33-37 in lbs
Load Resistors
17
Section III
How To... Replace The User Arms

Tools required: Allen wrench set and Phillips screwdriver 1. MODELS 8500 and 9100: Raise the BOOT COVERS on the UPPER ARMS. MODEL 9500: Remove four(4) mounting bolts from the USER ARM REAR COVERS and remove these covers. Remove three(3) MOUNTING BOLTS from each UPPER ARM and lift off the user arm. Units with Heart Rate, disconnect electrical connector. Install new user arms in reverse order.
2.
3.
Boot Cover
Model 8500/9100
User Arm Cover Screws
Lockwashers
User Arm Rear Covers User Arm Front Covers
User Arm Hex Head Cap Screws 2-pin Connector
Rocker Arm
Model 9500
Model 9500HR
18
How To... Replace The Polar Receiver

Tools required: Phillips screwdriver 1. MODELS 8500 / 9100: Remove four(4) mounting bolts from the two halves of the MONOCOLUMN COVER and separate. MODEL 9500: Remove four(4) mounting bolts from each USER ARM REAR COVER(2). Then remove four(4) mounting bolts from the MONOCOLUMN COVERS and separate the two halves. Locate the POLAR RECEIVER in the monocolumn and disconnect it from its jack.
Monocolumn Front Cover
2.
Polar Receiver Polar Receiver Foam Monocolumn Back Cover Monocolumn Screws
3.
4. Install a new POLAR RECEIVER in reverse order.

Models 8500 / 9100
User Arm Front Covers Polar Receiver Monocolumn Front Cover Monocolumn Rear Cover Monocolumn Screws
Model 9500
Polar Receiver Foam User Arm Front Covers
19
Section III
User Arm Cover Screws
How To... Replace Monocolumn Cover

Tools required: Phillips screwdriver 1. MODELS 8500 / 9100: Remove four(4) mounting bolts from the two halves of the MONOCOLUMN COVER and separate. MODEL 9500: Remove four(4) mounting bolts from each USER ARM REAR COVER(2). Then remove four(4) mounting bolts from the MONOCOLUMN COVERS and separate the two halves. Install new monocolumn covers in reverse order.
Monocolumn Front Cover
2.
3.
Monocolumn Back Cover Monocolumn Screws
Models 8500 / 9100
User Arm Cover Screws User Arm Front Covers Polar Receiver Monocolumn Front Cover Monocolumn Rear Cover Monocolumn Screws Model 9500 Polar Receiver Foam User Arm Front Covers
20
How To... Replace The Frame Cover

Tools required: Phillips screwdriver, Standard screwdriver, Allen wrench set, 3/8 Socket set, and Wrenches 1. Remove the REAR COVERS. See How ToRemove Rear Covers. Remove the FRONT COVER. Remove the FRAME COVER which is adhered to the frame with double-back tape. Install four(4) pieces of tape to the underside of the cover, then install the FRAME COVER.
2. 3.
4.
Front Cover
Frame Cover
Double-back Adhesive Tape (Four pieces)
21
Section III
How To... Replace The Front Cover

Tools required: Phillips magnetic screwdriver #2 1. Remove the FRONT COVER screws(6) and separate the front cover halves. Install new front cover in reverse order.
2.
Front Cover Screws
Front Cover Screws Left Front Cover Right Front Cover Frame
Front Cover Screws
22
How To... Replace The Battery

Tools required: Phillips magnetic screwdriver #2 1. Remove the FRONT COVER screws(6) and separate the front cover halves. Disconnect the BATTERY CABLES. Remove the battery mounting screws(2) and lift out the BATTERY. Install new battery in reverse order.
Battery Battery Cables
2. 3.
4.
Front Covers
23
Section III
How To... Replace The Rear Wheels and Axle

Tools required: Slotted screwdriver and Pliers 1. 2. 3. Remove the AXLE CAP from the WHEEL AXLE. Remove the WHEELS and AXLE. Install new wheels, axle, and axle cap in the reverse direction.
Rear Wheels
Wheel
Axle Cap
Axle Wheel
Axle Cap
24
How To... Replace The Endcaps

Tools required: Slotted screwdriver 1. 2. 3. Remove the endcaps from the LOWER ARMS. Remove the endcaps from the FRAME. Install new endcaps in reverse order.
Endcap
Endcaps
25
Section III
How To... Replace Pedal

Tools required: Clean cloth, water, and isopropyl alcohol 1. 2. 3. Remove the pedals from the pedal arm assemblies. Remove old tape. Using a clean cloth, carefully clean the surface areas using a misture of 50% water and 50% isopropyl alcohol. Make sure all adhesive is removed from the pedal and pedal arm assembly and make sure that surface areas are perfectly dried. Apply four(4) pieces of double-back adhesive tape the pedal arm assembly as shown. Reinstall the pedal and apply 30-40 psi clamp pressure for approximately 60 seconds or longer.
Pedal Arm Assembly
4.
5.
Double-back Adhesive Tape (4 pieces)
on
26
How To... Set Jumpers on CSAFE Card

Tools required: Phillips screwdriver 1. Remove six(6) screws from the FRONT COVER and separate the front cover halves. Set jumpers according to chart below. Reinstall FRONT COVERS.
Networking Cable Front Cover Frame, Bottom
2. 3.
JUMPER SETTINGS
JW1 OUT JW2 IN JW3 OUT JW4 OUT JW5 OUT JW6 IN
CSAFE Card Mounting Bracket
Front Cover
27
Section III
NOTES:
28
SECTION IV
ELECTRONICS OVERVIEW AND WIRING BLOCK DIAGRAMS
Section IV
ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD
Functional Description:
The Display Console Board is designed to work in conjunction with the Alternator Control Board. It reads the keypad input for changes or updates by the user, and refreshes the status LEDs, data display, and profile display matrix.
Connector P5 (Not applicable on 9500 with Display Lock only)
Display EPROM
Connector P7 Connector P2
Connector P1
Connector and Pin Functions

Connector
P1 is a 17 pin, ribbon connector that connects to the Overlay Board
Location
Pin
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 3 4 5 6 7 8 9 10
Functional Description
Ground Strobe Strobe Return Strobe Return Strobe Return Strobe Return Ground Start Strobe Return Strobe Return Ground VSYS POWER CONTROL (7-8VDC) RPM (5VDC) GROUND LOAD VBAT (6 VDC) NOT USED FLDCMD START VBAT (6VDC) VBAT (6VDC)
P2 is a 10 pin connects to the Alternator Control Board
ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD Continued
Connector
P5 is an 8 pin connector that connects the Life Pulse Board to the Console Board
Location
Pin
1 2 3 4 5 6 7 8 1 2 3
HR-ENABLE (3.8 VDC) KEY VSYS (7-8 VDC) VSYS (7-8 VDC) GROUND GROUND HR-D0 (4.7 VDC) HR-DI (4.7 VDC) +VCC (5VDC) SIGNAL GROUND
Note: Not applicable on CT9500 with Display Lock feature.
P7 is a 3 pin connector that comes from the Polar connector
Section IV
ELECTRONICS OVERVIEW - POWER CONTROL BOARD

TP1 TP4
The Power Control Board is designed to regulate the alternator voltage by modulating the field current. It regulates the pass current (RPM signal) from the Alternator to the Console, and the pass current from the alternator to the load resistor while providing supply voltage for the console.
TP2 Connector P2 Connector P3 Connector P1 TP3
Connector and Pin Functions

Connector
P1 is a Molex 11 pin connector that connects to the Console
Location
Pin
1 2 3 4 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5
START GND KEY VSYS LOADCMD RPM START VBAT (6VDC) GND
GND
GND GND GND RPM GND FIELD LOAD LOAD LOAD VALT (10VDC) VALT (10VDC) LOAD VSYS (7-8VDC) Keyed VSYS (7-8VDC) GND GND
P2 is a 12 pin connector that connects to the Alternator and Power Resistor
P3 is 4 pin connector (not used)

N/A
ELECTRONICS OVERVIEW ALTERNATOR
The 12 volt, 35 amp Alternator is designed to provide electrical power to the product, supply load resistance while providing electrical power, and provide the RPM signal from the AC TAP to the Alternator Control Board.
Connector Locations:
AC TAP TERMINAL
OUTPUT TERMINAL
FIELD TERMINALS R ETUR N GROUND TERMINAL
IT AT EXC
IO N
Section IV
WIRING BLOCK DIAGRAM FOR LC9500HR
NOTES:
Section IV
SECTION V
PARTS IDENTIFICATION
Section V
MODEL IDENTIFICATION and SERIAL NUMBER LOCATION
Model / Serial number
Life Fitness Model 8500 Cross-Trainer
MODEL CT85-0100-01
SN 100000-Up
Console AK61-00026-0001 Eng/Met Overlay AK61-00025-0001 Eng/Met Main Cable AK61-00015-0000 Console Spacer 0K61-05009-0000 Upper Arm (LT) AK61-00460-0003 Grips(2) 0K61-05008-0000 Install Hardware AK61-00040-0000 Instruction Bag AK61-00042-0000 Endcap (2) 0K61-06001-0001 Lower Arm Assembly(2) GK61-00002-0022 Clevis Covers Assembly(2) AK61-00062-0000) Grommet 0017-00042-0754 Front Cover (RT) 0K61-06200-0000 Front Cover (LT) 0K61-06210-0000 Pedal Arm (LT) GK61-00002-0005
Console Post Assembly AK61-00500-0005 Decal 0K61-01200-0000
Grips(2) 0K61-06003-0000 Upper Arm (RT) AK61-00460-0002 Boot(2) 0K61-06000-0000 Front Post Cover 0K61-06010-0002 Rear Post Cover 0K61-06020-0002
Pedal Arm (RT) GK61-00002-0006
Pedal Arm Covers (RT) 0K61-06320-0000 Inside AK61-00019-0002 Outside Rear Cover (RT) GK61-00002-0014 Plug (2) 0K14-01384-0000
Rear Cover (LT) GK61-00002-0013 Wheel(2) GK61-00002-0011 Cap 0017-00012-1066 Leveler(4) AK61-00035-0000
3
Pedal Arm Covers(LT) 0K61-06300-0000 Inside AK61-00019-0000 Outside 0K61-01226-0002(2) Decal
Endcap (4) 0K61-06002-0001
Section V
MODEL CT85-0100-01
SN 100000-Up
Tie Rod (2) GK61-00002-0020 Arm Extension 0K61-03004-0000 Bolt 0017-00101-1645
Bolt 0017-00101-1646 Nut 0017-00103-0137 Sleeve 0K61-01076-0000
Anit Lift Bracket (2) 0K61-04114-0000 Bolts (4) 0017-00101-1645 Roller Kit GK61-00002-0027 Drive Pulley Assembly AK61-00230-0001 Pulley 0K61-02409-0000 Magnet AK61-00044-0001 Pillow Block Bearings (2) 0K53-01181-0000
Pedal (2) GK61-00002-0010 Tape (4) 0K61-04115-0002
Drive Belt 0K61-02700-0000
Frame Cover GK61-00002-0003 Tape 0K61-04115-0002 Battery 0017-00003-0685
Alternator w/ Flywheel AK61-00250-0001 Alternator 0017-00009-0841 Alternator Belt 0K53-01184-0000 Intermediate Pulley Assembly AK61-00061-0000
Grommet (14) 0017-00042-0754 (2) Crank Arm Assembly GK61-00002-0021 Nut 0017-00103-0025 Bolt 0017-00101-1606 Keyway 0K53-01122-0000 Allen Screw 0017-00101-0333
Resistor Bracket Assembly GK61-00002-0024 Alternator Cable AK61-00017-0000
PCB GK61-00002-0023 Stand Off (4) 0017-00042-0320 Nut (4) 0017-00103-0008
MODEL CT91-0100-01
SN 100000-Up
Console- AK61-00024-0001 Eng/Met Overlay - AK61-00023-0001 Eng/Met Main Cable - AK61-00015-0000 Polar Cable - AK61-00014-0000 Console Spacer - 0K61-05009-0000 Accessory Tray - GK61-00002-0002
Console Post Assembly AK61-00500-0004 Decal 0K61-01200-0000 Grips(2) 0K61-06003-0000 Upper Arm (RT) AK61-00460-0002
Upper Arm (LT) AK61-00460-0003
Boot(2) 0K61-06000-0000
Front Post Cover 0K61-06010-0002 Rear Post Cover 0K61-06020-0002 Polar Receiver SK40-00045-0001 Foam Isolator 0K36-01059-0002
Grips(2) 0K61-05008-0000 Install Hardware AK61-00040-0000 Instruction Bag AK61-00043-0000 Endcap(2) 0K61-06001-0001 Lower Arm Assembly(2) GK61-00002-0022 Clevis Covers Assembly(2) AK61-00062-0000 Grommet 0017-00042-0754 Front Cover (RT) 0K61-06250-0000 Front Cover (LT) 0K61-06240-0000
Pedal Arm (RT) GK61-00002-0006
Pedal Arm Covers (RT) 0K61-06320-0001 Inside AK61-00056-0001 Outside Rear Cover (RT) AK61-00002-0016 Plug (2) 0K14-01384-0000
Pedal Arm (LT) GK61-00002-0005
Rear Cover (LT) AK61-00002-0015
Pedal Arm Covers (LT) 0K61-06300-0001 Inside AK61-00056-0002 Outside Decal 0K61-01230-0001(2)
Endcap(4) 0K61-06002-0001
Wheel(2) GK61-00002-0011
Leveler(4) AK61-00035-0000
5
Section V
MODEL CT91-0100-01
SN 100000-Up

Bolt 0017-00101-1646 Nut 0017-00103-0137 Sleeve 0K61-01076-0000
Anti Lift Bracket (2) 0K61-04114-0000 Bolts (4) 0017-00101-1645 Roller Kit GK61-00002-0027 Drive Belt 0K61-02700-0000 Alternator w/ Flywheel AK61-00250-0001 Alternator 0017-00009-0841 Alternator Belt 0K53-01184-0000 Intermediate Pulley Assembly AK61-00061-0000
Pedal (2) GK61-00002-0010 Tape (4) 0K61-04115-0002
Drive Pulley Assembly Frame Cover AK61-00230-0001 GK61-00002-0019 Pulley Tape 0K61-02409-0000 0K61-04115-0002 Magnet AK61-00044-0001 Battery 0017-00003-0685 Pillow Block Bearings (2) 0K53-01181-0000
Grommet (14) 0017-00042-0754 (2) Crank Arm Assembly GK61-00002-0021 Nut 0017-00103-0025 Bolt 0017-00101-1606 Keyway 0K53-01122-0000 Allen Screws 0017-00101-0333
Life Fitness Model 9500 Cross-Trainers
MODEL CT95-0100-15
SN 100000-Up
Polar Cable - AK61-00014-0000 Main Cable - AK61-00015-0000 Overlay - AK61-00054-0001 Eng/Met Console- AK61-00053-0001 Eng/Met HR Cable - AK61-00052-0002 Accessory Tray - GK61-00002-0002
Upper Arm (LT) AK61-00048-0002 Grips(2) 0K61-05008-0000 Instruction Bag Ak61-00049-0000 Install Hardware AK61-00050-0000 Front Boot Cover 0K61-06340-0002 Rear Boot Cover 0K61-06341-0002 Lower Arm Assembly(2) GK61-00002-0019 Pedal Arm (RT) GK61-00002-0006
Upper Arm (RT) AK61-00048-00012 Front Post Cover 0K61-06350-0002 Rear Post Cover 0K61-06351-0002 Polar Receiver SK40-00045-0001 Foam Insulator 0K36-01059-0002 Pedal Arm Covers (RT) 0K61-06320-0001 Inside AK61-00018-0003 Outside Plug (2) 0K14-01384-0000 Rear Cover (RT) AK61-00002-0016
Front Cover (RT) 0K61-06250-0000 Front Cover (LT) 0K61-06240-0000
Pedal Arm Covers (LT) 0K61-06300-0001 Inside AK61-00018-0001 Outside Decal 0K61-01222-0001(2)
Endcap (4) 0K61-06002-0001
Wheel(2) GK61-00002-0011
Leveler(4) AK61-00035-0000
Section V
MODEL CT95-0100-15
SN 100000-Up
Arm Extension 0K61-03004-0000 Bolt 0017-00101-1645
Tie Rod (2) GK61-00002-0020 Bolt 0017-00101-1646 Nut 0017-00103-0137 Sleeve 0K61-01076-0000 Pedal (2) GK61-00002-0010 Tape (4) 0K61-04115-0002
Anti Lift Bracket (2) 0K61-04114-0000 Bolts (4) 0017-00101-1645 Roller (2) 0K61-00002-0027 Drive Pulley Assembly AK61-00230-0001 Pulley 0K61-02409-0000 Magnet AK61-00044-0001
Drive Belt 0K61-02700-0000 Alternator w/ Flywheel AK61-00250-0001 Alternator 0017-00009-0841 Alternator Belt 0K53-01184-0000 Intermediate Pulley Assembly AK61-00061-0000
Pillow Block Bearings (2) 0K53-01181-0000
Grommet (14) 0017-00042-0754
Crank Arm Assembly GK61-00002-0021 Nut 0017-00103-0025 Bolt 0017-00101-1606 Keyway 0K53-01122-0000 Allen Screw 0017-00101-0333
MODEL CT95-0100-17
SN 103198-Up
Polar Cable AK61-00014-0000 Main Cable AK61-00015-0000 Overlay AK61-00076-0001 Eng/Met Console AK61-00075-0001 Eng/Met HR Cable AK61-00052-0002 Accessory Tray GK61-00002-0018
Upper Arm (RT) AK61-00048-00012

Front Post Cover 0K61-06350-0002 Rear Post Cover 0K61-06351-0002 Polar Receiver SK40-00045-0001 Foam Insulator 0K36-01059-0002
Upper Arm (LT) AK61-00048-0002 Grips(2) 0K61-05008-0000 Install Hardware AK61-00050-0000 Instruction Bag AK61-00049-0000 Front Boot Cover 0K61-06340-0002 Rear Boot Cover 0K61-06341-0002 Lower Arm Assembly(2) GK61-00002-0019 Pedal Arm (RT) GK61-00002-0006
Pedal Arm Covers (RT) 0K61-06320-0001 Inside AK61-00018-0003 Outside Plug (2) 0K14-01384-0000 Rear Cover (RT) AK61-00002-0016
Front Cover (RT) 0K61-06250-0000 Front Cover (LT) 0K61-06240-0000
Pedal Arm Covers (LT) 0K61-06300-0001Inside AK61-00018-0001Outside Decal 0K61-01222-0001(2)
Endcap (4) 0K61-06002-0001
Wheel(2) GK61-00002-0011
Leveler(4) AK61-00035-0000
Section V
MODEL CT95-0100-17
SN 103198-Up

Bolt 0017-00101-1646 Nut 0017-00103-0137 Sleeve 0K61-01076-0000
Anti Lift Bracket (2) 0K61-04114-0000 Bolts (4) 0017-00101-1645 Roller Kit GK61-00002-0027 Drive Pulley Assembly AK61-00230-0001 Pulley 0K61-02409-0000 Magnet AK61-00044-0001
Pedal (2) GK61-00002-0010 Tape (4) 0K61-04115-0002
Drive Belt 0K61-02700-0000 Alternator w/ Flywheel AK61-00250-0001 Alternator 0017-00009-0841 Alternator Belt 0K53-01184-0000 Intermediate Pulley Assembly AK61-00061-0000
Pillow Block Bearings (2) 0K53-01181-0000
Grommet (14) 0017-00042-0754 (2) Crank Arm Assembly GK61-00002-0021 Nut 0017-00103-0025 Bolt 0017-00101-1606 Keyway 0K53-01122-0000 Allen Screw 0017-00101-0333
10
NOTES:
11
Section V
SECTION VI
MISCELLANEOUS INFORMATION
Section VI
PREVENTIVE MAINTENANCE TIPS
Preventive Maintenance Schedule

DAILY Housing Inside Outside Clean Power Control Heatsink Connectors Board Console Assembly Overlay Mounting Bolts Connectors Alternator Belt Tension Brushes Flywheel Mechanical Main Drive Belt Oil Light Bearings Pedals Drive Pulley Clean Clean/Inspect Inspect Inspect and lube with non-detergent oil Inspect Inspect Clean/Inspect Clean Inspect Inspect Clean Inspect Inspect Clean MONTHLY BI-ANNUALLY
INSTALLATION INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS!

DO NOT locate the Cross-Trainer outdoors, near swimming pools, or in areas of high humidity. DO NOT operate your Cross-Trainer if it has been dropped, damaged, or even partially immersed
in water. Contact Life Fitness Customer Support Services at the number in the Operation Manual.
DO NOT locate the Cross-Trainer any closer than 30 inches ( 76 cm ) to a television set. DO NOT locate additional Cross-Trainers any closer than a minimum of 42 inches (107 cm) from
center to center to avoid interference (cross talk) between Heart Rate monitors.
DO keep the area around your Cross-Trainer clear of any obstructions, including walls and furniture. DO verify the contents of the delivery carton against the accompanying Parts Listing prior to setting
the cartons and shipping material aside. If any parts are missing, contact Life Fitness Customer Support Services at the number listed in the Operation Manual. Save the shipping cartons in case of return.
DO read the entire Operation Manual prior to attempting to operate this machine as this is essential
for proper use.
Section VI
INSTALLATION INSTRUCTIONS
TOOLS REQUIRED FOR ASSEMBLY... Magnetic #2 Bit Phillips Screwdriver, 5/16 & 3/16 Hex Key Wrenches, 1/2" Open End Wrench
Parts List
1 Hex Socket Head Cap Screw 3/8-16 x 1 0017-00101-1645 3 Phillips Pan Head Screw #8-18 x 3/4" 0017-00101-1242 5 Front Monocolumn Cover 0K61-06020-0002 (Model 9100) 0K61-06350-0002 (Model 9500HR) 7 9 11 Console Support Assembly AK61-00500-0004 Left Front Cover 0K61-06240-0000 Left User Arm Assembly Qty: 1 AK61-00460-0003 (Model 9100) AK61-00048-0002 (Model 9500HR) 13 15 17 Front Rocker Cover 0K61-06340-0002 (Model 9500HR Only) Foam Isolator (Polar Receiver) 0K36-01059-0002 Accessory Tray AK61-00045-0002 19 Acorn Nut 5/16-18 0017-00103-0287 21 23 Front Clevis Cover 0K61-06352-0002 Internal Lock Washer 0017-00104-0450 (Model 9500HR Only) 0K61-05009-0000 Qty: 2 Qty: 6 22 Back Clevis Cover 0K61-06353-0002 Qty: 2 Qty: 4 20 Qty: 1 18 Qty: 1 16 Qty: 2 14 Back Rocker Cover 0K61-06341-0002 (Model 9500HR Only) Polar Receiver AK40-00045-0001 Button Head Cap Screw 5/16-18 x 5/8" 0017-00101-1647 Console Spacer Qty: 1 Qty: 4 Qty: 1 Qty: 2 12 Qty: 1 10 Qty: 1 8 Qty: 1 6 (Model 9100) Qty: 14 (Model 9500HR) Qty: 18 4 Qty: 8 2 Phillips Pan Head Screw #8-16 x 3/4" 0017-00101-1148 Console Assembly AK61-00024-0001 (Model 9100) AK61-00053-0001 (Model 9500HR) Back Monocolumn Cover 0K61-06010-0002 (Model 9100) 0K61-06351-0002 (Model 9500HR) Flat Washer 0017-00104-0192 Right Front Cover 0K61-06250-0000 Right User Arm Assembly AK61-00460-0002 (Model 9100) AK61-00048-0001 (Model 9500HR) Qty: 1 Qty: 1 Qty: 2 Qty: 1 Qty: 1 Qty: 4
18
19
23
1
4
Step 1
Before proceeding, familiarize yourself with the parts of the Cross-Trainer and make sure that you have received all the items described in the Parts List.
9
Step 2
Locate the left and right FRONT COVER (#9, #10). Using two PHILLIPS PAN HEAD SCREWS (#3), mount the USER LEFT FRONT COVER (#9) to the FRAME (A). Attach the USER RIGHT FRONT COVER (#10) to the FRAME in the same manner using two PHILLIPS PAN HEAD SCREWS (#3). Secure the tops of the FRONT COVERS together using two PHILLIPS PAN HEAD SCREWS (#3).
3 A 10
12
11 D
Step 3 (Model 9100 Only)
Locate the LEFT USER ARM (#11). Secure the LEFT USER ARM to the LEFT ROCKER ARM (B) using three HEX SOCKET HEAD CAP SCREWS (#1). Repeat the procedure for the RIGHT USER ARM (#12) and RIGHT ROCKER ARM (C). Tighten all screws securely. Slide the BOOT COVERS (D) located on the user arms down over the mounting plates.
C B
(Model 9500HR Only)

Locate the LEFT USER ARM (#11). Snap the 2-PIN CONNECTOR (2PA) located at the bottom of the LEFT USER ARM into the 2-PIN CONNECTOR (2PB) positioned at the top of the LEFT ROCKER ARM (B). Feed the connectors and excess cable up into the LEFT USER ARM. Secure the LEFT USER ARM to the LEFT ROCKER ARM using three HEX SOCKET HEAD CAP SCREWS (#1) and INTERNAL LOCK WASHERS (#23). Repeat the procedure for the RIGHT USER ARM (#12) and RIGHT ROCKER ARM (C). Tighten all screws securely.
12 11 23 1 2PA
CAUTION: BE CAREFUL NOT TO PINCH THE WIRE HARNESSES WHEN ASSEMBLING THE USER ARMS (#11 & #12) TO THE ROCKER ARMS (B & C) (Model 9500HR Only).
B
Model 9500HR Shown
Section VI
2PB
Step 4 Detach and unwrap the WIRE HARNESS (E) (10P, 3P, (4P 9500HR Only)) located at the top of the MONOCOLUMN (F). Holding the CONSOLE SUPPORT ASSEMBLY (#7) with the handgrips facing upward, feed the WIRE HARNESS up through the neck and out the top access hole. Carefully lower the CONSOLE SUPPORT ASSEMBLY into the MONOCOLUMN. CAUTION: BE CAREFUL NOT TO PINCH THE WIRE HARNESS (E) WHEN ASSEMBLING THE CONSOLE SUPPORT ASSEMBLY (#7) TO THE MONOCOLUMN (F). Step 5 Using two HEX SOCKET HEAD CAP SCREWS (#1) and two FLAT WASHERS (#8), secure the CONSOLE SUPPORT ASSEMBLY (#7) to the MONOCOLUMN (F). Tighten the screws securely. Step 6 Locate the ACCESSORY TRAY (#17). Feed the WIRE HARNESS (E) through the center access hole. Place the ACCESSORY TRAY on the CONSOLE SUPPORT ASSEMBLY (#7) as shown. Using four BUTTON HEAD CAP SCREWS (#18) and ACORN NUTS (#19), secure the ACCESSORY TRAY to the CONSOLE SUPPORT ASSEMBLY through the large mounting holes. Tighten the screws securely. Step 7 Attach the 3-PIN (3P) and 10-PIN (10P) CONNECTORS to the corresponding jacks on the back of the CONSOLE ASSEMBLY (#4). (Model 9500HR Only)
3P 10P 20 17 4P
18
19
7 2 1
8 F Model 9500HR Shown
Attach the 4-PIN (4P) CONNECTOR to the corresponding jack on the back of the CONSOLE ASSEMBLY (#4). Step 8 Place the CONSOLE ASSEMBLY SPACER (#20) onto the CONSOLE SUPPORT ASSEMBLY (#7). Align the mounting holes in the CONSOLE ASSEMBLY SPACER with those in the CONSOLE SUPPORT ASSEMBLY. Step 9 Feed any excess WIRE HARNESS (E) down into the CONSOLE SUPPORT ASSEMBLY (#7). Secure the CONSOLE ASSEMBLY (#4) to the CONSOLE SUPPORT ASSEMBLY using four PHILLIPS PAN HEAD SCREWS (#2). Tighten the screws securely. CAUTION: DO NOT OVER-TIGHTEN THE PHILLIPS HEAD PAN SCREWS (#2). CAUTION: BE CAREFUL NOT TO PINCH THE WIRE HARNESS (E) WHEN ASSEMBLING THE CONSOLE ASSEMBLY (#4) TO THE CONSOLE SUPPORT ASSEMBLY (#7).
Step 10
Locate the POLAR RECEIVER (#16). Slide the FOAM ISOLATOR (#15) over the POLAR RECEIVER. Remove the POLAR RECEIVER JACK (G) located at the front of the MONOCOLUMN (F) near the PIVOT SHAFT (H) from the tape and plug the POLAR RECEIVER into the POLAR RECEIVER JACK.
5 G 16 H
Step 11
Locate the front and back MONOCOLUMN COVERS (#5 & #6). With the wire positioned on top, carefully insert the POLAR RECEIVER (#16) between the vertical ribs located inside the BACK MONOCOLUMN COVER (#6). Place the BACK MONOCOLUMN COVER (#6) over the PIVOT SHAFT (H) at the top of the MONOCOLUMN (F).
15 6 3
F Model 9100 Shown
NOTE: THE POLAR RECEIVER WIRE MUST BE POSITIONED ON TOP WHEN INSERTED INTO THE REAR MONOCOLUMN COVER (#6). Step 12 (Model 9100 Only)
Place the FRONT MONOCOLUMN COVER (#5) on the opposite side of the BACK MONOCOLUMN COVER (#6) to cover the PIVOT SHAFT (G) and CONSOLE SUPPORT ASSEMBLY MOUNTING SCREWS. Use four PHILLIPS PAN HEAD SCREWS (#3) to secure the MONOCOLUMN COVERS together. Tighten the screws securely.
Step 13 (Model 9500HR Only)

Place the FRONT MONOCOLUMN COVER (#5) on the opposite side of the BACK MONOCOLUMN COVER (#6) to cover the PIVOT SHAFT (G) and CONSOLE SUPPORT ASSEMBLY MOUNTING SCREWS. Interlock the top tabs and use two PHILLIPS PAN HEAD SCREWS (#3) to secure the bottoms of MONOCOLUMN COVERS together. Tighten the screws securely.
CAUTION: DO NOT OVER-TIGHTEN THE PHILLIPS PAN HEAD SCREWS (#3). Step 14 (Model 9500HR Only)
13
14 5 H
G 16
15 6 3 14
13
Model 9500HR Shown
3
7
Section VI
Locate one FRONT ROCKER COVER (#13) and one BACK ROCKER COVER (#14). Position the FRONT ROCKER COVER over the user side of the left end of the PIVOT SHAFT (F) (as shown) making sure that it interlocks with the MONOCOLUMN COVERS (#5 & #6). Place the BACK ROCKER COVER over the opposite side of the left end of the PIVOT SHAFT in the same manner. Secure the covers using three PHILLIPS PAN HEAD SCREWS (#3). Repeat the procedure reversing front and back for the user right end of the pivot shaft.
Step 15
Rotate the LEFT ROCKER ARM (B) to its fullest rear position. Locate one FRONT CLEVIS COVER (#21) and one BACK CLEVIS COVER (#22). Position the BACK CLEVIS COVER at the LEFT CLEVIS JOINT (J). Hook the bottom tabs of the FRONT CLEVIS COVER into the bottom of the BACK CLEVIS COVER and pivot the FRONT CLEVIS COVER upward to fully meet the BACK CLEVIS COVER. Secure the CLEVIS COVERS to the LEFT ROCKER ARM using two PHILLIPS PAN HEAD SCREWS (#3). Tighten the screws securely.
B
21 22 3
PRE-OPERATION CHECKLIST
4 Ensure that all fasteners are tight. 4 Make sure the CROSS-TRAINER is properly leveled and stable.
(Refer to the Operation Manual)
4 Ensure that the Leveler Jam Nuts are tight.

(Refer to the Operation Manual)
4 Read the entire Operation Manual before using the Cross-Trainer.
Before attempting to operate your Cross-Trainer, it is imperative that you familiarize yourself with the contents of the Operation Manual. If your Cross-Trainer does not respond as described in the OPERATION MANUAL, contact the nearest Life Fitness service center as listed in the Operation Manual.
UNPACKAGING INSTRUCTIONS
Step 1 Remove all staples from the corrugated shipping container and fold down the four sides of the base tray (A). Step 2 Lift and open the top flaps of the shipping container sleeve (B). Lift and remove the two front support posts (C). Step 3 With the help of another person, carefully lift the shipping container sleeve (B) up and off of the base tray (A) and over the Cross-Trainer (D). Remove the ship kit box (E) from the Cross-Trainer and set aside. Remove the remaining corner posts (F) and ship kit support (G). Step 4 Using a screwdriver, remove the rear locator pad (H) from the base tray (A). Step 5 Carefully lift the front of the unit and slowly roll the unit backward beyond the flattened base tray. Step 6 Follow the Installation Instructions included in the parts bag to complete the assembly of your Cross-Trainer.
Ship Kit Contents: Left & Right User Arms Console Support Assembly Left & Right Front Covers Display Console Front & Back Monocolumn Covers Hardware Kit Installation Instructions Polar Receiver Kit ( 9100 / 9500HRR Only ) Reading Rack Assembly
D H F C
( 9500HRR Only ) Heart Rate Monocolumn Covers ( 5500HR Only ) Line Cord (International Only) Power Supply Polar Transmitter Kit
IMPORTANT
SAVE YOUR PACKING MATERIALS IN CASE OF
9
Section VI
COMMUNICATING BY FAX
If you would like to submit a parts order, or if you need help troubleshooting a problem, we have included, for your convenience, a FAX form on the following page. Simply make a copy (or copies) of the FAX sheet and fill in the necessary information. You may FAX us at any time, 24 hours a day, to either of the numbers shown. A Life Fitness service representative will process your order, or respond to your problem, as quickly as possible.
10
CUSTOMER SUPPORT SERVICES

PARTS ORDER
( IF BOTH PLEASE INDICATE )
SALE WARRANTY
DATE:
PRODUCT TROUBLESHOOTING
NAME: CUSTOMER NO:
PHONE:
FAX:
CONTACT NAME:
METHOD OF SHIPMENT: PARTS ORDER FORM

ITEM NO. 1 2 3 4 5 6 PART NUMBER
1 DAY
2 DAY
GROUND
DESCRIPTION
QUANTITY
PRODUCT TROUBLESHOOTING
PRODUCT NAME: DETAILED DESCRIPTION OF PROBLEM: SERIAL NO.
PRODUCT NAME: DETAILED DESCRIPTION OF PROBLEM:
SERIAL NO.
TIME RECEIVED:
TIME COMPLETED:
TECHNICIAN NAME:
11
Section VI
10601 W. Belmont Ave., Franklin Park IL 60131 PHONE (800) 351-3737 Toll Free or (708) 451-0036 FAX (800) 216-8893 Toll-Free or (708) 288-3702
CUSTOMER SUPPORT SERVICES
12
NOTES:
13

m05100k61b014 Ct85 - 91 - 95HR SVC Manual

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Models 8500, 9100, and 9500HR Total Body Cross-Trainers with Rear Drive System

Customer Support Services

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers TERMINOLOGY

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

TABLE OF CONTENTS Continued

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

TABLE OF CONTENTS Continued

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Dirt build up in pedal tracks. Rear roller wheels frozen.

Link cover contacting rear cover.

Excessive disk wobble.

Faulty intermediate shaft assembly. Faulty pillow block. Alternator.

Bearings at pivot points are out of position or dirty.

Setscrews or crankarm bolt in crankarm assembly are loose.

Small extension arm bolt loose. Faulty link bearings. 2

Link mounting loose.

Clean, lubricate, and retighten.

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Excessive end play in rocker arms.

Upper Arms feel loose.

Front to back play in pedal lever.

Poly V-Pulley on intermediate shaft is loose. Crankarm loose.

Faulty display console.

Faulty power control board.

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Defective chest strap or improperly positioned.

No heart rate reading.

Faulty cable connection.

Loose or malfunctioning heart rate lead connection at Display Console.

Heart-rate (DSP) Board (CT9500HR) is faulty or not communicating.

Malfunctioning Display Console.

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

No LEDs or random LEDs lit.

Cable connection faulty.

Main wire harness damaged.

No RPM. Unit shuts off one minute into program.

Bad cable connection.

Auto start failure

Bad cable connection.

Faulty reed switch or board.

Dead battery after C-Safe card is installed.

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

CT8500, CT9100, and CT9500HR Display Consoles

Level Time RPM Calories

Heart Rate Distance

Cal/Hour Watts Time RPM

Heart Rate Distance

Quick Workout Display Lock

Start Start Enter Enter

Start Enter Enter

CT9500HR (Display Lock Equipped)

Level Time RPM Calories

Heart Rate Distance

Heart Rate Distance